Does this sound like an actuator problem?

Wed Oct 28, 2009 1:39 am

Am dealing with the frankly hilarious number of problems this damn Alto Works has, and I've now come to the boost issue, or rather lack of it since I put the turbo from a Wagon R Wide on it. Now I was prepared for a slight increase in lag due to the bigger size of the turbo, but when I hooked up my boost gauge this weekend the results were depressing.

I started to make boost at around 2,800rpm but then it was only getting up to 0.75 bar (still lower than I should get with this turbo and a stock setup) at around 5,500rpm which is a joke! Tried to do what little testing I knew how to by removing the turbo to intercooler piping and firing up the engine. When I revved the engine at idle I could feel a fair amount of air being pushed through so I don't think it's the turbo part of the setup that's buggered.

A little research on the net brought me to the conclusion that the wastegate could be stuck open or the actuator isn't working for some reason. Do you reckon that's a fair assessment at the moment? And is there any quickfire way of testing these two with the turbo still on the car? I really don't feel like taking half the front of the car away to get it out again.

Cheers for any help you can offer me

Wed Oct 28, 2009 9:46 am

11PSI sounds like what a Wagon R+ would run standard. I think the actuator is doing its job as per its factory setting. If you want more boost, you'll need a bleed valve or EBC.

Wed Oct 28, 2009 9:49 am

Brayden wrote:11PSI sounds like what a Wagon R+ would run standard. I think the actuator is doing its job as per its factory setting. If you want more boost, you'll need a bleed valve or EBC.

I thought the Wagon R Wide produced 0.9bar. And it definitely shouldn't be spooling at about 5,500rpm.

Wed Oct 28, 2009 10:27 am

Try disconnecting the wastegate actuator line and take it for a gentle drive. If the boost doesn't go above 11PSI then there's a problem with the actuator or the turbo itself.

WARNING: I say "gentle" drive because without the actuator line connected the boost level can technically hit the maximum level of what the turbo/motor can produce. So don't go giving it a bootfull.

Wed Oct 28, 2009 11:16 pm

I might just do that a little later and see what happens. I mean... what's the worst that could happen!

Wed Oct 28, 2009 11:43 pm

did this on my f6b, but wasnt so gentle, boost gauge cleared 30psi in a hell of a hurry before engine stalled

tried it later on a dyno, the operator said it was actually blowing the fuel back up the injectors

strangely enough my engine blew up not too long after, never figured out why

Thu Oct 29, 2009 12:32 am

gazuga wrote:did this on my f6b, but wasnt so gentle, boost gauge cleared 30psi in a hell of a hurry before engine stalled
tried it later on a dyno, the operator said it was actually blowing the fuel back up the injectors
strangely enough my engine blew up not too long after, never figured out why

Yeah, I'll try not to "boost Blitz"!!!

Thu Oct 29, 2009 2:25 am

Well I pulled off the hose going from turbo to actuator and took it for a gentle drive. Even with my foot floored the onset of boost was very laggy. It might have peaked a little higher than before but it was still only doing that at about 5,500-6,000rpm

Thu Oct 29, 2009 9:33 am

That would suggest that the actuator is seized, or the turbo bushes are stuffed.

Thu Oct 29, 2009 9:40 am

Brayden wrote:That would suggest that the actuator is seized, or the turbo bushes are stuffed.

Or I've got boost leaks. Any way to check the first 2?

Thu Oct 29, 2009 11:36 am

It would need to be an absolute colossal boost leak to make the turbo spool up that late. Trust me, you'd hear it!

Only way to check the actuator/turbo bushes is to remove it and inspect.

Thu Oct 29, 2009 2:00 pm

Apply some air pressure to the waste gate actuator first and see if you can see the kinkage move. It might give you a clue as to what's going on.

Thu Oct 29, 2009 8:32 pm

use a bike pump to apply the air pressure to the wastegate actuator....NOT an air compressor (for obvious reasons).

my money is on;
1. Jammed or rusted wastegate. Unbolt your actuator from the compressor housing and see if you can open and close (pull and push) the wastegate.
2. Boost leak, but would have to major like a boot not on at all or the pipe for the reticulator/blow off valve is open to the atom.
3. Blocked intercooler

Remember load makes boost so it may even be an intake blockage restricting the turbo.....

Thu Oct 29, 2009 9:13 pm

ike849 wrote:use a bike pump to apply the air pressure to the wastegate actuator....NOT an air compressor (for obvious reasons).

my money is on;
1. Jammed or rusted wastegate. Unbolt your actuator from the compressor housing and see if you can open and close (pull and push) the wastegate.
2. Boost leak, but would have to major like a boot not on at all or the pipe for the reticulator/blow off valve is open to the atom.
3. Blocked intercooler

Remember load makes boost so it may even be an intake blockage restricting the turbo.....

I'll try that and see if the actuator actually moves. The BOV is definitely connected up but I'm going to try and cover everything in the next few days and sort out where my problem lies. Thanks for the advice.

Sun Nov 01, 2009 10:03 pm

A little update on my progress (or lack thereof) with this issue. This evening I pulled the hose off the actuator and fitted up a bike pump to it. Gave it a bit of pressure and could see the actuator arm moving smoothly as pressure built up and then subsided. So at least the actuator side of that is working. I don't know if it's possible for the arm to move and the wastegate to still not open but I'm thinking maybe not.

On Friday night I also replaced a fair few vacuum lines although all seemed in good condition. I also made sure that everything was in the right place, and as far as I could tell it was all as it should be.

So I'm not sure what to do now. All I know is I've lost almost all semblance of spool since I put this turbo on, and even with the stock ECU and injectors I should be getting much more power off this. Surely if there's that big a vacuum leak I'd be able to hear it loudly. I can hear a noise when I go into boost, but I'm thinking it's just the turbo spooling rather than a huge leak. Thinking of just going back to the stock turbo but it was a bitch to swap originally. Just can't work out what else it could be though. For the record, the turbo has no shaft movement at all.